Thin light emitting diode and fabrication method

ABSTRACT

A method for fabrication a light emitting diode (LED) includes forming alternating material layers on an LED structure, formed on a substrate, to form a reflector on a back side opposite the substrate. A handle substrate is adhered to a stressor layer deposited on the reflector. The LED structure is separated from the substrate using a spalling process to expose a front side of the LED structure.

BACKGROUND

1. Technical Field

The present invention relates to light emitting diode (LED) structuresand methods, and more particularly to thin LEDs made by wafer splittinggrowth substrates employed in growing the LEDs.

2. Description of the Related Art

GaN-based light-emitting diodes (LEDs) are becoming mainstream as theycan provide emitted light wavelengths for general lighting applications,medical applications, etc. However, growth substrates on which LEDstructures are grown are expensive. In addition to substrate reuse,potentially superior performance of thin LED devices has been a maindriving force for selecting thin LED structures over other LED types.For example, more effective heat dissipation strategies can be employedto improve the lifetime of thin LEDs. To improve the intensity of theemitted light in thin LEDs, distributed Bragg reflectors (DBR) and/ortexturing of the starting substrate have been employed.

SUMMARY

A method for fabrication a light emitting diode (LED) includes formingalternating material layers on an LED structure, formed on a substrate,to form a reflector on a back side opposite the substrate. A handlesubstrate is adhered to a stressor layer deposited on the reflector. TheLED structure is separated from the substrate using a spalling processto expose a front side of the LED structure.

A method for fabrication a light emitting diode (LED) includes growing acrystalline LED structure on a growth substrate, forming alternatingmaterial layers on the LED structure to form a reflector on a back sideopposite the growth substrate and depositing a stressor layer on thereflector. A handle substrate is adhered to the stressor layer. The LEDstructure is separated from the growth substrate using a spallingprocess to expose a front side of the LED structure.

Another method for fabricating a light emitting diode (LED) includesgrowing a crystalline LED structure on a growth substrate; formingalternating material layers on the LED structure to form a reflector ona back side opposite the growth substrate; patterning the reflector toform openings in the reflector; depositing a stressor layer on thereflector and in the openings to form localized contacts; adhering ahandle substrate to the stressor layer; and separating the LED structurefrom the growth substrate using a spalling process to expose a frontside of the LED structure.

A light emitting diode (LED) includes a crystalline LED structureincluding a plurality of alternating crystalline layers, a distributedBragg reflector (DBR) formed on a back side of the LED structure andincluding alternating material layers and a stressor layer formed on thereflector. A substrate is adhered to the stressor layer. A conductivematerial is formed on a front side of the LED structure such that thefront side is configured to permit emission of light.

These and other features and advantages will become apparent from thefollowing detailed description of illustrative embodiments thereof,which is to be read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

The disclosure will provide details in the following description ofpreferred embodiments with reference to the following figures wherein:

FIG. 1 is a cross-sectional view of a light emitting diode structureformed on a buffer layer which is formed on a growth substrate inaccordance with the present principles;

FIG. 2 is a cross-sectional view of the light emitting diode structureof FIG. 1 having a reflector, stressor layer and handle substrate formedthereon in accordance with the present principles;

FIG. 3 is a cross-sectional view of the light emitting diode structureof FIG. 2 showing the growth substrate removed from the buffer layerusing spalling and the stress induced by the stressor layer inaccordance with the present principles;

FIG. 4 is a cross-sectional view of the light emitting diode structureof FIG. 3 showing the buffer removed in accordance with the presentprinciples;

FIG. 5 is a cross-sectional view of the light emitting diode structureof FIG. 4 showing a metal electrode patterned on the LED structure inaccordance with the present principles;

FIG. 6 is a cross-sectional view of a light emitting diode structureformed on a buffer layer which is formed on a growth substrate andshowing a reflector patterned and a metal layer formed on and inopenings of the reflector in accordance with the present principles;

FIG. 7 is a cross-sectional view of the light emitting diode structureof FIG. 6 having a stressor layer formed on the reflector and in theopening in the reflector and a handle substrate formed thereon inaccordance with the present principles;

FIG. 8 is a cross-sectional view of the light emitting diode structureof FIG. 7 showing the growth substrate removed from the buffer layerusing spalling and the stress induced by the stressor layer inaccordance with the present principles;

FIG. 9 is a cross-sectional view of the light emitting diode structureof FIG. 8 showing the buffer removed in accordance with the presentprinciples;

FIG. 10 is a cross-sectional view of the light emitting diode structureof FIG. 9 showing a metal electrode patterned on the LED structure inaccordance with the present principles; and

FIG. 11 is a block/flow diagram showing a method for fabricating an LEDin accordance with illustrative embodiments.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In accordance with the present principles, light emitting diodestructures are provided with high quality back reflectors which may beformed on a stressor layer and handle substrate. The stressor layer isalso employed to induce stress for the removal a growth substrate in thefabrication process. The reflectors preferably include distributed Braggreflectors (DBRs) and/or dielectric reflectors which are grown on top ofthe LED structure prior to the removal of the LED structure from thegrowth substrate. The removal of the growth substrate is preferablyperformed using a mechanical splitting process, e.g., using controlledspalling technology.

It is to be understood that the present invention will be described interms of a given illustrative architecture having a wafer or substratefor forming LEDs; however, other architectures, structures, substratematerials and process features and steps may be varied within the scopeof the present invention.

It will also be understood that when an element such as a layer, regionor substrate is referred to as being “on” or “over” another element, itcan be directly on the other element or intervening elements may also bepresent. In contrast, when an element is referred to as being “directlyon” or “directly over” another element, there are no interveningelements present. It will also be understood that when an element isreferred to as being “connected” or “coupled” to another element, it canbe directly connected or coupled to the other element or interveningelements may be present. In contrast, when an element is referred to asbeing “directly connected” or “directly coupled” to another element,there are no intervening elements present.

In accordance with some embodiments, a design for an integrated circuitchip may be created in a graphical computer programming language, andstored in a computer storage medium (such as a disk, tape, physical harddrive, or virtual hard drive such as in a storage access network). Ifthe designer does not fabricate chips or the photolithographic masksused to fabricate chips, the designer may transmit the resulting designby physical means (e.g., by providing a copy of the storage mediumstoring the design) or electronically (e.g., through the Internet) tosuch entities, directly or indirectly. The stored design is thenconverted into the appropriate format (e.g., GDSII) for the fabricationof photolithographic masks, which typically include multiple copies ofthe chip design in question that are to be formed on a wafer. Thephotolithographic masks are utilized to define areas of the wafer(and/or the layers thereon) to be etched or otherwise processed.

Methods as described herein may be used in the fabrication of integratedcircuit chips. The resulting integrated circuit chips can be distributedby the fabricator in raw wafer form (that is, as a single wafer that hasmultiple unpackaged chips), as a bare die, or in a packaged form. In thelatter case the chip is mounted in a single chip package (such as aplastic carrier, with leads that are affixed to a motherboard or otherhigher level carrier) or in a multichip package (such as a ceramiccarrier that has either or both surface interconnections or buriedinterconnections). In any case the chip is then integrated with otherchips, discrete circuit elements, and/or other signal processing devicesas part of either (a) an intermediate product, such as a motherboard, or(b) an end product. The end product can be any product that includesintegrated circuit chips, ranging from toys and other low-endapplications to advanced computer products having a display, a keyboardor other input device, and a central processor.

It should also be understood that material compounds will be describedin terms of listed elements, e.g., AlGaN, GaN, InGaN, etc. Thesecompounds may include different proportions of the elements within thecompound, e.g., InGaN includes In_(x)Ga_(1-x)N, where x, is less than orequal to 1, or AlGaN includes Al_(x)Ga_(1-x)N where x is less than orequal to 1, etc. In addition, other elements may be included in thecompound, such as, e.g., AlInGaN, and still function in accordance withthe present principles. The compounds with additional elements will bereferred to herein as alloys.

The present embodiments may be part of a device or circuit, and thecircuits as described herein may be part of a design for an integratedcircuit chip, a display device, etc.

Reference in the specification to “one embodiment” or “an embodiment” ofthe present principles, as well as other variations thereof, means thata particular feature, structure, characteristic, and so forth describedin connection with the embodiment is included in at least one embodimentof the present principles. Thus, the appearances of the phrase “in oneembodiment” or “in an embodiment”, as well any other variations,appearing in various places throughout the specification are notnecessarily all referring to the same embodiment.

It is to be appreciated that the use of any of the following “/”,“and/or”, and “at least one of”, for example, in the cases of “A/B”, “Aand/or B” and “at least one of A and B”, is intended to encompass theselection of the first listed option (A) only, or the selection of thesecond listed option (B) only, or the selection of both options (A andB). As a further example, in the cases of “A, B, and/or C” and “at leastone of A, B, and C”, such phrasing is intended to encompass theselection of the first listed option (A) only, or the selection of thesecond listed option (B) only, or the selection of the third listedoption (C) only, or the selection of the first and the second listedoptions (A and B) only, or the selection of the first and third listedoptions (A and C) only, or the selection of the second and third listedoptions (B and C) only, or the selection of all three options (A and Band C). This may be extended, as readily apparent by one of ordinaryskill in this and related arts, for as many items listed.

Referring now to the drawings in which like numerals represent the sameor similar elements and initially to FIG. 1, an illustrative LEDstructure 10 is shown in accordance with one illustrative embodiment.The LED structure 10 includes a growth substrate 12, which may includeany number of monocrystalline substrate materials. In some embodiments,the growth substrate 12 may include III-nitrides (GaN, InN, AlN, etc.),III-arsenides, III-phosphides, sapphire, silicon, etc. A buffer layer 14may be epitaxially grown on the growth substrate 12 and can be grownusing the same material or a different monocrystalline material with anearly similar lattice constant (e.g., AlN or GaN).

A first contact layer 16 includes a doped crystalline material that maybe epitaxially grown on the buffer layer 14. In one embodiment, thecontact layer 16 includes GaN. The GaN of the contact layer 16 can alsoact as a buffer (buffer layer 16 may be omitted) as well as a contactlayer. A superlattice or alternating layer stack 18 is formed on thefirst contact layer 16. The stack 18 may include a multiple quantum well(MQW) structure.

The stack 18 preferably includes a multiple quantum well (MQW) structurethat may include alternating layers of InGaN and GaN or alternatinglayers of AlGaN and (In)GaN or alternating layers of AlGaN and GaN,wherein the wider gap material serves as the barrier and the narrowergap material acts as the well. The composition and the thickness of boththe barrier and the well are engineered to adjust the wavelength of theemitted light. Other materials may also be employed. The layers 20, 22of stack 18 may be about 3-9 nm per GaN/InGaN period. Usually, multipleperiods are used for higher power devices, e.g., 3 to 8 periods arecommon, making the stack 18 thickness as thick as, e.g., 100 nm.

The layers 20, 22 of stack 18 may be crystalline and epitaxially grown.A second contact layer 24 includes a doped crystalline epitaxially grownmaterial having an opposite dopant conductivity than the first contactlayer 16. The contact layers 16 and 24 may respectively include n-dopedGaN and p-doped GaN. The contact layers 16 and 24 may be about 500 nmthick but can be made any thickness, e.g., if thinner, the contactlayers 16 and 24 need to have a higher doping concentration. Dependentupon the application, thinner contact layers 16 and 24 can enable higherlight extraction as well.

A back reflector 30 is formed on the second contact layer 24. Thereflector 30 may include a distributed Bragg reflector (DBR), which is areflector formed from multiple layers of alternating materials 26, 28with varying refractive index, or by periodic variation of somecharacteristic (such as height) of a dielectric waveguide, resulting inperiodic variation in the effective refractive index in the guide. Eachboundary of layers 26, 28 causes a partial reflection of an opticalwave. The reflections combine with constructive interference, and thelayers 26, 28 act as a high-quality reflector. In illustrative examples,the layers 26, 28 may include material combinations of, e.g., AlGaN/GaN,TiO₂/SiO₂, Al₂O₃/SiO₂, etc. In one embodiment, the reflector layers 26,28 include dielectric materials. In other embodiments, the reflectivelayers 26, 28 may include doped semiconductor materials, e.g., AlGaN/GaNforming, e.g., p+ DBR or n+ short super-lattice reflectors. Multiplereflectors may also be employed together.

Referring to FIG. 2, a stressor layer 32 is formed on the reflector 30.Thin reflective metal (20 nm-500 nm) such as Au, Al, or Ag may bedeposited on the reflector prior to the deposition of the stressor layer32. The stressor layer 32 may include a metal, or a dielectric material.For example, the stressor layer 32 may include Ni, organic materials,etc. The stressor layer 32 is preferably a tensile stressor layer toinduce stress for spalling the growth substrate 12 as will be described.The stressor layer 32 is preferably a metal between about 2 to about 100microns thick. A flexible handle substrate 34 is adhered to the stressorlayer 32. The flexible handle substrate 34 may include any substratematerial suitable for supporting the stressor layer 32 and assisting inwafer splitting. The flexible handle substrate 34 may include a polymer,a ceramic, or other material.

Referring to FIG. 3, the growth substrate 12 may be split off orotherwise reduced using controlled spalling. In a particularly usefulembodiment, spalling offers a relatively inexpensive, low-temperaturemethod for splitting the growth substrate 12. Shear stress is appliedusing the flexible handle substrate 34 and the applied stress due to thestressor layer 32 to split the growth substrate 12 along a fracture line36. The fracture line 36 preferably includes an interface between thegrowth substrate 12 and the buffer layer 14, if employed or the contact16 if the buffer layer is not employed.

Referring to FIG. 4, the device 10 is flipped after removing the growthsubstrate 12. The buffer layer 14, if employed, is now removed by one ormore of etching, polishing, grinding, etc. For a dry etch, a chlorinebased chemistry, etc. may be employed to remove the buffer layer 14 (andany remaining portion of the growth substrate 12) down to the contact16. The stressor layer 32 remains as a portion of the device 10 and, ifconductive, acts as a portion of the back contact of the device 10.

Referring to FIG. 5, an optional transparent passivation layer (notshown) may be deposited and patterned. A front metal grid 40 may bedeposited and patterned on the contact 16. The metal grid 40 may form aportion of the front contact 16. During operation the device 10, whichincludes, an LED or thin LED, light 42 is emitted from the front face(contact 16).

Referring to FIG. 6, beginning with the LED device structure of FIG. 1,the back reflector 30 of device 100 is patterned by forming a mask (notshown) and etching trenches or holes 54 therein. The etching process mayinclude a reactive ion etch or other suitable etching process. The maskmay be removed by known processes. The reflector 30 may includedielectric layers 26, 28. In one embodiment, the dielectric layers 26,28 include Al₂O₃ and SiO₂, although other materials may be employed. Thedielectric layers 26, 28 may be formed by employing, e.g., a plasmaenhanced chemical vapor deposition (PECVD) process. A metal layer 52 isselectively deposited on horizontal surfaces or may be conformallydeposited and etched to remove metal from vertical surfaces to formlocalized contacts. Other processes may be employed. The metal layer 52may include Au, Al, Ag or any other suitable conductor.

Referring to FIG. 7, a stressor layer 56 is formed on the metal layer 52and fills trenches or holes 54. The stressor layer 56 may include ametal, or a dielectric material. For example, the stressor layer 56 mayinclude Ni, organic materials, etc. The stressor layer 56 is preferablya tensile stressor layer to induce stress for spalling the growthsubstrate 12 as will be described. The stressor layer 56 is preferably ametal between about 2 to about 100 microns thick. A flexible handlesubstrate 34 is adhered to the stressor layer 56. The flexible handlesubstrate 34 may include any substrate material suitable for supportingthe stressor layer 56 and assisting in wafer splitting. The flexiblehandle substrate 34 may include a polymer, a ceramic, or other material.

Referring to FIG. 8, the growth substrate 12 may be split off orotherwise reduced using the controlled spalling. In a particularlyuseful embodiment, spalling offers a relatively inexpensive,low-temperature method for splitting the growth substrate 12. Shearstress is applied using the flexible handle substrate 34 and the appliedstress due to the stressor layer 56 to split the growth substrate 12along a fracture line 58. The fracture line 36 preferably includes aninterface between the growth substrate 12 and the buffer layer 14, ifemployed or the contact 16 if the buffer layer is not employed.

Referring to FIG. 9, the device 100 is flipped after removing the growthsubstrate 12. The buffer layer 14, if employed, is now removed by one ormore of etching, polishing, grinding, etc. For a dry etch, a chemicalmechanical polishing (CMP) or a chlorine-based chemistry, etc. may beemployed to remove the buffer layer 14 (and any remaining portion of thegrowth substrate 12) down to the contact 16. The stressor layer 56remains as a portion of the device 100 and acts as a portion of the backcontact of the device 100 with localized conductive portions betweenportions of the reflector(s) 30.

Referring to FIG. 10, an optional transparent passivation layer (notshown) may be deposited and patterned. A front metal grid 40 may bedeposited and patterned on the contact 16. The metal grid 40 may form aportion of the front contact 16 of the device 100. During operation ofthe device 100, which includes, an LED or thin LED, light 42 is emittedfrom the front face (contact 16).

Referring to FIG. 11, a method for fabricating an LED is shown inaccordance with illustrative embodiments. It should also be noted that,in some alternative implementations, the functions noted in the blocksmay occur out of the order noted in the figures. For example, two blocksshown in succession may, in fact, be executed substantiallyconcurrently, or the blocks may sometimes be executed in the reverseorder, depending upon the functionality involved. It will also be notedthat each block of the block diagrams and/or flowchart illustration, andcombinations of blocks in the block diagrams and/or flowchartillustration, can be implemented by special purpose hardware-basedsystems that perform the specified functions or acts, or combinations ofspecial purpose hardware and computer instructions.

In block 202, a crystalline LED structure is grown on a growthsubstrate, e.g., by epitaxial growth. The LED structure may include amultiple quantum well (MQW) structure sandwiched between two contactswith opposite dopants conductivities. In block 204, a crystalline bufferlayer may be formed on the growth substrate, and the LED structure maybe formed on the buffer layer.

In block 206, alternating material layers are provided on the LEDstructure to form a reflector on a back side opposite the growthsubstrate. The alternating material layers may include an epitaxiallygrown distributed Bragg reflector (DBR) or alternating dielectric layersto form the DBR. In block 208, in one embodiment, the reflector may bepatterned to form openings in the reflector. In block 210, a metalcontact layer may be formed on or in the patterned reflector.

In block 212, a stressor layer is deposited on the reflector. In block214, if the reflector is patterned, the stressor layer is formed in theopenings to form localized contacts. The localized contacts may contactthe LED structure through the reflector (e.g., using the metal contactlayer). In block 216, a handle substrate is adhered to the stressorlayer.

In block 218, the LED structure is separated from the growth substrateto expose a front side of the LED structure. A spalling process isemployed for the layer transfer. The LED structure is separated, e.g.,by spalling using stress provided by the stressor layer.

In block 220, if a buffer layer is employed, separating the LEDstructure may include splitting the growth substrate from the bufferlayer. The buffer layer can then be etched to remove the buffer layerfrom the LED structure in block 222. If the buffer layer is notemployed, the split may be made at or near the interface with the LEDstructure.

In block 224, processing continues. The LED structure may be removedfrom the stressor layer to transfer the LED to another substrate ordevice. The LED structure may remain connected to the stressor layer andthe handle substrate, and operated in that configuration.

Having described preferred embodiments for thin light emitting diode andfabrication method (which are intended to be illustrative and notlimiting), it is noted that modifications and variations can be made bypersons skilled in the art in light of the above teachings. It istherefore to be understood that changes may be made in the particularembodiments disclosed which are within the scope of the invention asoutlined by the appended claims. Having thus described aspects of theinvention, with the details and particularity required by the patentlaws, what is claimed and desired protected by Letters Patent is setforth in the appended claims.

What is claimed is:
 1. A method for fabricating a light emitting diode(LED), comprising: forming alternating material layers on an LEDstructure, formed on a substrate, to form a reflector on a back sideopposite the substrate; adhering a handle substrate to a stressor layerdeposited on the reflector; and separating the LED structure from thesubstrate using a spalling process to expose a front side of the LEDstructure.
 2. The method as recited in claim 1, further comprisingforming a buffer layer on the substrate and forming the LED structure onthe buffer layer.
 3. The method as recited in claim 2, whereinseparating the LED structure includes splitting the substrate from thebuffer layer and etching the buffer layer to remove the buffer layerfrom the LED structure.
 4. The method as recited in claim 1, whereinforming alternating material layers includes epitaxially growingdistributed Bragg reflectors (DBR).
 5. The method as recited in claim 1,wherein forming alternating material layers includes depositingalternating dielectric layers to form distributed Bragg reflectors(DBR).
 6. The method as recited in claim 1, wherein separating the LEDstructure includes spalling the substrate by employing stress providedby the stressor layer.
 7. The method as recited in claim 1, wherein theLED structure includes a multiple quantum well (MQW) structure.
 8. Themethod as recited in claim 1, wherein the LED structure includes GaN. 9.A method for fabricating a light emitting diode (LED), comprising:forming alternating material layers on an LED structure, formed on asubstrate, to form a reflector on a back side opposite the substrate;patterning the reflector to form openings in the reflector; adhering ahandle substrate to a stressor layer deposited on the reflector; andseparating the LED structure from the substrate using a spalling processto expose a front side of the LED structure.
 10. The method as recitedin claim 9, further comprising forming a buffer layer on the substrateand forming the LED structure on the buffer layer.
 11. The method asrecited in claim 10, wherein separating the LED structure includessplitting the substrate from the buffer layer and etching the bufferlayer to remove the buffer layer form the LED structure.
 12. The methodas recited in claim 9, wherein forming alternating material layersincludes epitaxially growing distributed Bragg reflectors (DBR).
 13. Themethod as recited in claim 9, wherein forming alternating materiallayers includes depositing alternating dielectric layers to formdistributed Bragg reflectors (DBR).
 14. The method as recited in claim9, wherein separating the LED structure includes spalling the substrateby employing stress provided by the stressor layer.
 15. The method asrecited in claim 9, wherein the LED structure includes a multiplequantum well (MQW) structure.
 16. The method as recited in claim 9,wherein localized contacts are formed by depositing the stressor layerin the openings, the localized contacts contacting the LED structurethrough the reflector.